Apparatus for forming a foam product

Abstract

An apparatus and method for forming flat top foam buns or slabs which features positioning solely one sheet of film material to each side of a rising foam body. The single side sheet is positioned in contact with the rising foam on one side and in contact with a rigid side wall on the opposite side. Also, the single side sheet positioned between the rising foam and stationary side wall represents the only material between the side wall and foam material. The side film has a bottom edge which originates below a reference plane lying flush on the bottom supporting surface of the foam bun once it has reached an essentially full rise position. Preferably, bottom and side conveyors are provided near the full rise position of the foam material and the side film is redirected from an upwardly inclined edge arrangement to a horizontal edge arrangement. Unwind assemblies are provided exterior to each of the side walls and are positioned such that the side sheets extend from a downstream position toward an upstream edge of the side walls, are wrapped around the upstream edge of the side walls and then directed at an incline. Roller sets or the like are provided to maintain the preset incline or a plurality of inclines of the film despite the disruptive forces of the expanding foam. The inclined side sheets help offset the side height reducing shear forces which develop between the rising foam and noninclined side film or side wall.